engine coolant ISUZU AXIOM 2002 Service Owner's Manual

6A±18
ENGINE MECHANICAL (6VE1 3.5L)
Malfunction Indicator Lamp
The instrument panel ªCHECK ENGINEº Malfunction In-
dicator Lamp (MIL) illuminates by self diagnostic system
when the system checks the starting of engine, or senses
malfunctions.
Condition
Possible causeCorrection
ªCHECK ENGINEº MIL does not
illuminate at the starting of engine
Bulb defectiveReplace
illuminate at the starting of engineMIL circuit openCorrect or replace
Command signal circuit to operate
self diagnostic system shortedCorrect or replace
Powertrain Control Module (PCM)
cable loosely connected,
disconnected or defectiveCorrect or replace
PCM defectiveReplace
ªCHECK ENGINEº MIL illuminates,
and stays onDeterioration of heated oxygen
sensor internal elementReplace
Heated oxygen sensor connector
terminal improper contactReconnect properly
Heated oxygen sensor lead wire
shortedCorrect
Heated oxygen sensor circuit openCorrect or replace
Deterioration of engine coolant
temperature sensor internal elementReplace
Engine coolant temperature sensor
connector terminal improper contactReconnect properly
Engine coolant temperature sensor
lead wire shortedCorrect
Engine coolant temperature sensor
circuit openCorrect or replace
Throttle position sensor open or
shorted circuitsCorrect or replace
Deterioration of crankshaft position
sensorReplace
Crankshaft position sensor circuit
open or shortedCorrect or replace
Vehicle speed sensor circuit openCorrect or replace
Manifold absolute pressure sensor
circuit open or shortedCorrect or replace
Intake air temperature sensor circuit
open or shortedCorrect or replace
Fuel injector circuit open or shortedCorrect or replace
PCM driver transistor defectiveReplace PCM
Malfunctioning of PCM RAM
(Random Access Memory) or ROM
(Read Only Memory)Replace PCM

6A±35
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head
Removal
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
6. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
7. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.

Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
1. Loosen head bolts in reverse of tightening
sequence.
2. Remove cylinder head assembly.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
Installation
1. Install cylinder head assembly to cylinder block.
A. Put cylinder head gasket on the cylinder block.
NOTE: There is discrimination mark ªRº for right bank
and ªLº for left bank on the cylinder head gasket as shown
in the illustration.
Do not reuse cylinder head gasket.
011RW005
B. Align dowel pin hole to dowel pin on the cylinder
block.
C. Position cylinder head on the cylinder block.
D. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
E. Using J-24239-01 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.

6A±37
ENGINE MECHANICAL (6VE1 3.5L)
Valve Stem Oil Controller , Valve Spring and Valve Guide
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.

Drain engine coolant.
3. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head in
this manual.
4. Remove camshaft.

Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using J-8062 valve spring
compressor and J-42898 valve spring compressor
adapter then remove upper valve spring seat and
lower seat.
014RW042
7. Remove oil controller using J-37281 oil controller
remover, remove each valve stem oil controller.
8. Remove valve guide using J-37985 valve guide
replacer.
Installation
1. Install valve guide using J-42899 valve guide installer.
2. Install oil controller using J-38537 oil controller
installer.
3. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using J-8062 valve spring compressor
and J-42898 valve spring compressor adapter to
install the split collars.
014RW042
4. Install tappet with shim.
5. Install camshaft assembly.

Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.

Refer to installation procedure for Cylinder Head in
this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.

6A±46
ENGINE MECHANICAL (6VE1 3.5L)
Engine Assembly
Removal
035R200001
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges
before removal in order to return the hood to original
position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect Ion sensing module harness connectors,
and manifold absolute pressure sensor harness
connectors from sensor on common chamber.
7. Disconnect throttle position sensor harness
connectors from throttle body.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of front
axle and remove transmission harness bracket from
engine left side.
14. Disconnect ground cable between engine and frame.
15. Disconnect bonding cable connector on the back of
right dash panel.
16. Disconnect bonding cable terminal on the left bank.
17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from radiator.
20. Remove radiator upper and lower hoses.21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
23. Move drive belt tensioner to loose side using wrench
then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering pump
along with piping on the body side.
25. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
on the body side.
26. Remove four O
2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side of
vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts from
engine mount on chassis side.
35. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
36. Remove engine assembly.

6A±48
ENGINE MECHANICAL (6VE1 3.5L)
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 N´m (16 lb ft)
M10 bolts : 43 N´m (32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N´m (16 lb ft)
M10 bolts : 46 N´m (34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect throttle position sensor harness
connector.
025RY001
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
27. Reconnect manifold absolute pressure sensor
harness connectors.
28. Reconnect ion sensing module connectors as shown
in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
29. Install engine hood to the original position.

Refer to installation procedure for Body section in
this manual.

6B±2
ENGINE COOLING (6VE1 3.5L)
General Description
030RW001
Legend
(1) Water Pump
(2) Thermostat
(3) Radiator
(4) Reserve Tank
(5) Cooling Fan
(6) Cylinder Block(7) Cylinder Head
(8) Right Bank
(9) Throttle Body
(10) Cylinder Block
(11) Cylinder Head
(12) Left Bank
(13) Heater
The cooling system is a pressurized Engine Coolant (EC)
forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
the radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001

ENGINE COOLING (6VE1 3.5L)6B±3
Thermostat
The thermostat is a wax pellet type with a air hole(1) and is
installed in the thermostat housing.
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 ~ 117.6
kPa (12.8 ~ 17.0 psi) pressure. (No oil cooler provided for
M/T)
110RW023
Antifreeze Solution

Relation between the mixing ratio and freezing
temperature of the EC varies with the ratio of
anti±freeze solution in water. Proper mixing ratio can
be determined by referring to the chart. Supplemental
inhibitors or additives claiming to increase cooling
capability that have not been specifically approved by
Isuzu are not recommended for addition to the cooling
system.
Calculating mixing ratio
F06RW005
NOTE: An t if r e e ze s o lu t io n + Water = Total cooling
system capacity.

Total Cooling System Capacity

A/T 10.0Lit (2.64Us gal)
B06RW002

6B±4
ENGINE COOLING (6VE1 3.5L)

Mixing ratio
Check the specific gravity of engine coolant in the
cooling system temperature ranges from 0
C to 50
C
using a suction type hydrometer, then determine the
density of the engine coolant by referring to the table.
B06RW003
Diagnosis
Engine Cooling Trouble
ConditionPossible causeCorrection
Engine overheatingLow Engine Coolant levelReplenish
Incorrect fan installedReplace
Thermo meter unit faultyReplace
Faulty thermostatReplace
Faulty Engine Coolant temperature
sensorRepair or replace
Clogged radiatorClean or replace
Faulty radiator capReplace
Low engine oil level or use of
improper engine oilReplenish or change oil
Clogged exhaust systemClean exhaust system or replace
faulty parts
Faulty Throttle Position sensorReplace throttle valve assembly
Open or shorted Throttle Position
sensor circuitRepair or replace
Damaged cylinder head gasketReplace
Engine overcoolingFaulty thermostatReplace
Engine slow to warm±upFaulty thermostatReplace
Thermo unit faultyReplace

ENGINE COOLING (6VE1 3.5L)6B±5
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the ªMINº
and ªMAXº lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the ªMAXº line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.
WARNING: T O AV O I D T H E D A N G E R O F B E I N G
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to ªMAXº line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to ªPº (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 ~ 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the ªMAXº line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.

6B±6
ENGINE COOLING (6VE1 3.5L)
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley(3) Water Pump Assembly
(4) Gasket
Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to ªTiming Beltº in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced.

Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N´m (18 lb ft)

Tightening order
The tightening order are in the illustrate.NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
030RW008
3. Idle pulley

Install idle pulley and tighten bolt to the specified
torque.
Torque: 52 N´m (38 lb ft)
4. Timing belt

Install timing belt. Refer to timing belt installation
step in ªTiming Beltº in this manual.
5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.